U.S. patent application number 11/427280 was filed with the patent office on 2006-11-16 for power distribution module for personal recreational vehicle.
Invention is credited to James Larson, Raymond A. Schoenfelder.
Application Number | 20060256543 11/427280 |
Document ID | / |
Family ID | 32107527 |
Filed Date | 2006-11-16 |
United States Patent
Application |
20060256543 |
Kind Code |
A1 |
Larson; James ; et
al. |
November 16, 2006 |
POWER DISTRIBUTION MODULE FOR PERSONAL RECREATIONAL VEHICLE
Abstract
A power distribution module for a personal recreational vehicle
includes a housing and a cover. The housing defines an interior and
includes a wall having an array of receptacle openings. The
receptacle openings are adapted to receive and secure electrical
components inside the housing. A distribution harness includes a
plurality of electrical conductors and is coupled to the housing
wherein the electrical conductors are in electrical communication
with the electrical components inside the housing. The power
distribution module can optionally include a decal to assist quick
and accurate placement of the electrical components during the
manufacturing process. A method for producing a personal
recreational vehicle having a standardized housing over a range of
models. The housing includes a component arrangement guide for
locating and installing electrical components.
Inventors: |
Larson; James; (Newfolden,
MN) ; Schoenfelder; Raymond A.; (Zumbrota,
MN) |
Correspondence
Address: |
BLACK LOWE & GRAHAM, PLLC
701 FIFTH AVENUE
SUITE 4800
SEATTLE
WA
98104
US
|
Family ID: |
32107527 |
Appl. No.: |
11/427280 |
Filed: |
June 28, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
10283427 |
Oct 29, 2002 |
7072188 |
|
|
11427280 |
Jun 28, 2006 |
|
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Current U.S.
Class: |
361/826 |
Current CPC
Class: |
B60R 16/0239
20130101 |
Class at
Publication: |
361/826 |
International
Class: |
H02B 1/20 20060101
H02B001/20 |
Claims
1. A power distribution module for a personal recreational vehicle
comprising: a housing defining an interior, including a component
attachment portion and a cover, the housing further including a
plurality of receptacle openings in a wall in the component
attachment portion, wherein the receptacle openings are
spaced-apart and adapted for receiving and securing electrical
components within the housing; and a distribution harness having a
plurality of electrical conductors, wherein the electrical
conductors electrically cooperate with the receptacle openings to
connect to the electrical components, wherein the conductors are
adapted to distribute power.
2. The power distribution module of claim 1, wherein the receptacle
openings are spaced-apart in an array.
3. The power distribution module of claim 1, wherein each array has
four columns and each column contains ten receptacle openings.
4. The power distribution module of claim 1, wherein the cover is a
removable cover.
5. The power distribution module of claim 3, wherein the removable
cover is removably secured to the component attachment portion with
a latch and a catch arrangement.
6. The power distribution module of claim 3, wherein the cover is
removable with one hand by a user.
7. The power distribution module of claim 1, further including a
plurality of electrical components, each electrical component
seated in a corresponding receptacle opening, and wherein the
electrical components are selected from a group comprising
resistors, capacitors, diodes and fuses.
8. The power distribution module of claim 1, wherein the housing
further includes a component arrangement guide located adjacent the
wall having the receptacle openings, wherein the component
arrangement guide indicates the location of the electrical
components to be integrated with the harness.
9. The power distribution module of claim 9, wherein the component
arrangement guide is a decal.
10. The power distribution module of claim 1, wherein the housing
is waterproof when the cover is secured to the component attachment
portion.
11. The power distribution module of claim 1, further including: a
plurality of cable ties securing the harness to the housing, a
first cable tie securing a first section of the harness to a first
tie down, and a second cable tie securing a second section of the
harness to a second tie down.
12. A personal recreational vehicle comprising: an electrical
distribution system for distributing electrical signals and power,
the electrical distribution system including a power distribution
module, wherein at least a portion of the electrical signals and
power passes through the power distribution module, the power
distribution module including; a housing having a plurality of
receptacle openings in a wall, wherein the receptacle openings are
spaced-apart in an array and adapted for receiving electrical
components; and a distribution harness having a plurality of
electrical conductors, wherein the electrical conductors
electrically cooperate with the receptacle openings for receiving
electrical components.
13. The personal recreational vehicle of claim 12, wherein the
housing further includes: first and second mating portions adapted
to be secured together; the first mating portion including a catch;
the second mating portion including a latch, wherein the latch
engages the catch to secure the first and second portions together
when latch and catch are engaged.
14. The personal recreational vehicle of claim 13, wherein the
first and second mating portions form a waterproof interior section
when secured together.
15. The personal recreational vehicle of claim 13, wherein the
first and second mating portions are adapted to be disengaged by a
user using one hand.
16. The personal recreational vehicle of claim 12, further
including a plurality of electrical components, each electrical
component seated in a corresponding receptacle opening, and wherein
the electrical components are selected from a group comprising
resistors, capacitors, diodes and fuses.
17. The personal recreational vehicle of claim 12, wherein the
housing further includes a component arrangement guide located
adjacent the wall having the receptacle openings, wherein the
component arrangement guide indicates the location of the
electrical components to be integrated with the harness.
18. The personal recreational vehicle of claim 17, wherein the
component arrangement guide is a decal.
19. A power distribution system for an ATV comprising: a
distribution harness for distributing power and electrical signals
adapted to be connected to electrical components; and means for
connecting the distribution harness to the electrical
components.
20. The power distribution system of claim 19, wherein the means
includes first and second mating portions adapted to form a
waterproof interior section.
21. The power distribution system of claim 19, wherein the means
includes a plurality of receptacle openings spaced-apart in an
array.
22. The power distribution system of claim 21, wherein the array
has four columns and each column contains ten receptacle
openings.
23. A method of producing a plurality of personal recreational
vehicle models, each model having a common housing for a power
distribution module, wherein the power distribution module includes
a plurality of receptacle openings passing from an interior to an
exterior of the housing, the method comprising: placing a component
arrangement guide adjacent the receptacle openings on the interior
side of the housing, the component arrangement guide having a
schematic indicating placement of electrical components; installing
a plurality of electrical components into a plurality of positions
in the receptacle openings, each component being installed in a
position indicated by the component arrangement guide; and
connecting each electrical component to an associated electrical
conductor, each electrical conductor disposed outside the
housing.
24. The method of claim 23, wherein said step of placing the
component arrangement guide includes placing a decal.
25. The method of claim 23, wherein said step of installing
includes installing electrical components including at least one
fuse and at least one component selected from the group consisting
of resistors, capacitors, and diodes.
Description
FIELD OF THE INVENTION
[0001] The invention relates generally to personal recreational
vehicles, and more particularly to a power distribution module for
use with engines that power personal recreational vehicles.
BACKGROUND OF THE INVENTION
[0002] Personal recreational vehicles, such as snowmobiles and
ATVs, are used by millions of people for sport and fun. To
illustrate, snowmobiling is a sport enjoyed by individuals of all
ages and walks of life. Although interest in snowmobiling has
traditionally been considerable, in recent years the sport has seen
its popularity soar. For example, according to the International
Snowmobile Manufacturers Association, about 82,000 snowmobiles were
sold in the United States in 1992. By 1997, that number topped
170,000 units.
[0003] Similarly, the number of Americans driving off-road vehicles
such as ATVs increased from 19.4 million in 1983 to 27.9 million in
1995. The increase in use of personal recreational vehicles is
partly due to technological advancements of the equipment, advances
that have made use safer and easier for persons of differing levels
of ability.
[0004] For example, snowmobiles have become more comfortable,
responsive and maneuverable, resulting in a more pleasing and
exciting riding experience for the driver. One advancement of
particular importance is the improvement in the maneuverability and
stability of snowmobiles. As these characteristics have advanced, a
greater number of individuals have been drawn to the sport. The
industry has kept pace with the growth in the sport by expanding
the number of models available across a range of prices. ATVs have
seen similar types of changes and improvements.
[0005] The growing popularity of personal recreational vehicles
puts an increased demand on manufacturers to reduce cost of the
vehicles. One way manufacturers can reduce cost is to standardize
components, both within and across a product line. Standardization
reduces manufacturing cycle time as well as cost.
[0006] All personal recreational vehicles include some type of
power distribution system for routing and control of power and
signals throughout the vehicle. The power distribution system
usually includes a fuse box, with individual fuses blowing when the
fuse rated power is exceeded. Other components such as diodes and
relays are housed in other locations.
[0007] For the reasons stated, it is desirable to devise a means by
which the power distribution module can be easily standardized for
manufacturing. Additionally, it is also desirable to have a power
distribution module that includes components other than fuses.
SUMMARY OF THE INVENTION
[0008] Against this backdrop, the invention has been created. One
aspect of the present invention is directed to a power distribution
module for a personal recreational vehicle. The power distribution
module includes a housing defining an interior and including a
component attachment portion and a cover. The housing further
includes a plurality of receptacle openings in a wall in the
component attachment portion, and the receptacle openings are
spaced-apart and adapted for receiving and securing electrical
components within the housing. The power distribution module
further includes a distribution harness having a plurality of
electrical conductors, wherein the electrical conductors
electrically cooperate with the receptacle openings to connect to
the electrical components, and the conductors are adapted to
distribute power.
[0009] Another aspect of the present invention is directed to a
personal recreational vehicle having an electrical distribution
system for distributing electrical signals and power. The
electrical distribution system includes a power distribution
module, wherein at least a portion of the electrical signals and
power passes through the power distribution module. The power
distribution module includes a housing having a plurality of
receptacle openings in a wall, and the receptacle openings are
spaced-apart in an array and adapted for receiving electrical
components. The power distribution module also includes a
distribution harness having a plurality of electrical conductors,
and the electrical conductors electrically cooperate with the
receptacle openings for receiving electrical components.
[0010] Another aspect of the invention is directed to a power
distribution system for a personal recreational vehicle including a
distribution harness for distributing power and electrical signals
adapted to be connected to electrical components; and means for
connecting the distribution harness to the electrical
components.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 depicts an ATV incorporating an example embodiment of
the power distribution module of the present invention.
[0012] FIG. 2 is a perspective view of an example of an embodiment
of a power distribution module of the present invention.
[0013] FIG. 3 is a perspective view from the opposite side of the
power distribution module of FIG. 2.
[0014] FIG. 4 is an elevational view of the cover for a power
distribution module shown in FIGS. 2 and 3.
[0015] FIG. 5 is a top view of the cover of FIG. 4.
[0016] FIG. 6 is a bottom view of the cover of FIG. 4.
[0017] FIG. 7 is an elevational view of the power distribution
module shown in FIGS. 2 and 3.
[0018] FIG. 8 is a top view of the power distribution module of
FIG. 7.
[0019] FIG. 9 is a bottom view of the power distribution module of
FIG. 7.
[0020] FIG. 10 is an end view of the component attachment module of
FIG. 7.
[0021] FIG. 11 is a schematic of a decal indicating the layout of
electrical components for use in a power distribution module having
a 4 by 10 array of receptacle openings in accordance with an
example embodiment of the present invention.
[0022] FIG. 12 is a section view of an example embodiment of a
catch and latch assembly in the open position for use as a
one-handed opening mechanism according to the present
invention.
[0023] FIG. 13 is a section view of an example embodiment of a
catch and latch assembly in the open position for use as a
one-handed closed mechanism according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0024] In general, the present disclosure discusses a power
distribution module for use in a vehicle. The power distribution
module tile is capable of being made water-resistant and opens and
closes using a one-handed operation, and includes other desirable
properties.
[0025] FIG. 1 depicts an ATV 100 with a steering mechanism 102 that
controls the orientation of a set of front wheels 106 via a
steering shaft 104. The steering shaft 104 couples the steering
mechanism 102 with the front wheels 106 via tie rods (not shown)
that connect the steering shaft 104 to the suspension system (not
shown) of the front wheels 106. The details regarding the coupling
of the steering shaft 104 and the suspension system for the wheels
106 vary from ATV to ATV and are known and are not the focus of the
present invention. Therefore, they are not discussed further. As
the steering mechanism 102 is turned, the front wheels 106 also
turn, thereby controlling the direction in which the ATV 100 moves.
An engine 108 is mounted toward the front of the chassis of the ATV
100. The engine provides power to the drive train (not shown) of
the ATV 100. The details of the drive train vary from ATV to ATV,
but according to the present invention, the ATV will have a power
distribution module 110 to control the flow of power and electrical
signals. The power distribution module will typically be located on
a portion of the frame of the ATV near the engine compartment.
However, the location can vary depending on the ATV. Similarly, the
power distribution module of the present disclosure can be used on
a snowmobile, and its use and placement are dictated by
considerations similar to those in using the power distribution in
an ATV.
[0026] Referring generally to FIGS. 2-10, an example of an
embodiment of a power distribution module 210 of the present
invention is shown. Power distribution module 210 is adapted for
housing and securing electrical components to protect them from
inclement operating conditions. Power distribution module 210
includes a housing 220, the housing 220 defining an interior, and a
distribution harness 260. The housing 220 includes a component
attachment portion 230 adapted to receive and hold electrical
components (not shown). Electrical components are held in place in
receptacle openings 232 in a wall 231 of the housing 220. The
receptacle openings 232 are spaced apart and adapted to receive and
secure electrical components within the housing, as will be
discussed further.
[0027] In the example embodiment shown, the housing 220 includes a
component attachment portion 230 and a removable cover 250.
Preferably, when the cover 250 is removably secured to the
component attachment portion 230 of the housing 220, a waterproof
seal is formed, keeping the electrical components protected in the
interior of the housing 220 free from condensation or other aqueous
materials, such as oil or mud, that can cause the electrical
components to have a shortened life or fail. One of skill in the
art will recognize that many modifications could be made to make
the housing waterproof, such as a lip and a gasket.
[0028] A latch 252 on the cover 250 may engage with a catch 240 on
the component attachment portion 230 to removably secure the cover
250 in place. An advantage of the example embodiment shown is that
a user can remove the cover 250 from the component attachment
portion 230 using only one hand, as will be discussed further
below, by disengaging each latch 252 from its catch 240. This is
especially helpful when accessing the power distribution module
210, which may not be easily accessible. This allows for easy
access to the electrical components in the event that one needs to
be replaced, since the power distribution module 210 is typically
located in a small and cluttered space. The cover 250 also can be
seated in place by engaging one or more stops 238 protruding from
an outer surface 237 of the component attachment portion 230. When
the cover 250 is secured to the component attachment portion 230,
the electrical components in the interior are protected from the
elements. Optionally, one or more mounting brackets 244 can be
included on the housing 220 for connecting to a complementary
mating portion (not shown) located on the ATV frame to releasably
secure the power distribution module 210.
[0029] Referring to FIGS. 12-13, shown is an exemplary embodiment
of a latch 252 and catch 240 arrangement that allows for one-handed
removal and placement of the cover 250 on the component attachment
portion 230, such as that shown in FIGS. 1-2. Catch 240 includes a
distal end 281 and a proximal end 282. Proximal end 282 of catch
240 is attached to the cover 250. Proximal end 282 includes an
arcuate section 283 that forms a pocket 284 between depending
section 285 of catch 240 and the cover 250. Pocket 284 holds a
sealing member 285, for example, a gasket or O-ring. Distal end 281
of catch 240 includes an engagement member 286. Catch 240 also
includes a resilient portion 287 that allows the distal end 281 of
catch 240 to move towards and away from the cover 250. The
resilient portion 287 biases the catch 240 into an engagement
position away from the cover 250 when there is no force applied to
catch 240. Catch 240 also includes a finger engagement portion 288.
Force F1 applied to the finger engagement portion 288 moved the
distal end 281 of the catch 240 towards the cover 250. Catch 240
includes a flange member 290 extending from the wall of the
component attachment portion 230. The flange member 290 includes a
distal portion 291 located away from the component attachment
portion 230. A protruding shoulder 292 projects from the distal end
291 of the flange member 290, forming a catch receiving area 293
there between. Latch 252 also includes an arcuate section 294 for
receiving into the pocket 284 of catch 240.
[0030] FIG. 12 shows the cover 250 and component attachment portion
230 with the cover 250 disengaged. FIG. 13 shows the cover 250
engaged with the component attachment portion 230, whereby a
watertight seal is formed. Beginning from the disengaged position,
cover 250 is engaged with the component attachment portion 230 by
inserting the distal end 281 of the catch 240 into the catch
receiving area 293 of the latch 252. As the catch 240 moves into
the engagement position with the latch 252, a ramp 289 engages the
upper end 296 of the shoulder 292, creating an inward force F1 that
moves the distal end 281 of the catch 240 towards the cover 250.
The catch 240 is moved into the catch receiving area 293 until the
engagement member 286 of the catch 240 clears the lower end 295 of
the shoulder 292, removing the inward force F1 from the distal end
281 of the catch 240. Upon removal of the force, the resilient
portion 287 of the catch 240 returns the catch 240 to the unbiased
position and the engagement member 286 of the catch 240 engages the
lower end 295 of the shoulder 292, securing the cover 250 onto the
component attachment portion 230.
[0031] A watertight seal is formed by the sealing member 285 being
compressed into the pocket 284 by the arcuate section 294 of the
latch 252. Preferably, the pocket 284 runs around the entire
periphery of the cover 250, and the sealing member 285 is made from
one piece of material, minimizing the chance that leak points
exist. Compression of the sealing member 285 also creates a
compressive force that holds the engagement member 286 against the
lower end 295 of the shoulder 292, creating an interference fit
that keeps the cover 250 secured.
[0032] Referring to FIGS. 1-2 & 12-13, to remove the cover 250
from the component attachment portion 230 via a one-handed
operation, a force F2 is applied to the finger engagement portion
288 of each catch 240, moving each catch 240 towards the cover 250
until the engagement member 286 clears the shoulder 292. The
compressive force stored in the sealing member 285 then moves the
cover 250 slightly away from the component attachment portion 230
and the cover 250 can be completely removed from the component
attachment portion 230, allowing access to the components.
[0033] Referring generally to FIGS. 2-10, the power distribution
module 210 may be mounted to a distribution harness 260. The
distribution harness 260 includes a plurality of electrical
conductors 262, which optionally can be housed within a sheath 269
to keep the conductors 262 in a bundle. Each electrical conductor
262 optionally may include an insulating covering (not shown). Each
electrical conductor 262 goes into an associated receptacle opening
232, and is in electrical communication with an electrical
component secured into receptacle openings 232 inside the housing.
One or more electrical components are secured into the receptacle
openings 232 in the housing 220. The electrical components can be
of any type typically used in power distribution systems, such as
resistors, capacitors, diodes and fuses.
[0034] Referring to FIGS. 2 and 3, the distribution harness 260
preferably is secured to the housing 220 to keep the conductors 262
in an orderly bundle. In the example embodiment shown, a first
cable tie 264 secures a first section 265 of the distribution
harness 260 to a first cable tie down 234 on the component
attachment portion 230 of the housing 220, and a second cable tie
266 secures a second section 267 of the distribution harness 260 to
a second cable tie down 236 on the component attachment portion 230
of the housing 220. Optionally, a third cable tie 268 can secure
conductors in the bundle at a third section 269 between the first
and second sections 265, 267 of the distribution harness 260. The
third cable tie 268 also secures conductors or other elements in
the distribution harness 260 that do not contain termination points
into the receptacle openings 232.
[0035] Referring to FIG. 9, in the example embodiment shown, the
receptacle openings 232 are arranged in an array 242 of rows and
columns having a regular spacing. The spacing can be selected so
that the array 242 is adapted to receive and secure standardized
electrical components. An advantage of having the array 242 of
receptacle openings 232 with a regular spacing pattern is
standardized electrical components can be located and installed
easily in the power distribution module. Preferably, the array 242
spacings are identical in the transverse T and lateral L
directions. More preferably, the spacing is such that the
receptacle openings 232 are arranged to receive ATO.TM. or ATC.TM.
specification electrical components.
[0036] Referring to FIG. 11, a component arrangement guide 300 is
shown. Preferably, component arrangement guide 300 is a decal. A
decal allows for easy identification and location of electrical
components across product and model lines by placing the decal over
the receptacle opening (232 as seen in FIGS. 3 and 9). The
electrical components can then be easily located and installed. In
the example embodiment shown, component arrangement guide includes
a schematic for placing fuses 302, diodes 304, and a relay 306 in
the receptacle openings of a power distribution module. The use of
the decal allows each component to be easily located and installed
into its proper receptacle opening, and also allows for easy
identification of a specific component location if it needs to be
replaced during maintenance.
[0037] An advantage of the power distribution module of the present
invention is that it can be used across a variety of models of
personal recreational vehicle by using a standardized housing
common to the models. A method of producing a plurality of personal
recreational vehicle models is accomplished using the standardized
power distribution module, thereby saving time and increasing
product quality by allowing a reduction in inventory of parts
specific to each model and also allowing for accurate placement of
the electrical components during assembly. The power distribution
module includes a plurality of receptacle openings passing from an
interior to an exterior of the housing and is assembled into the
personal recreational vehicle. By placing a component arrangement
guide adjacent the receptacle openings on the interior side of the
housing, the electrical components can be quickly and accurately
installed. The component arrangement guide includes a schematic
indicating placement of electrical components. Preferably, the
component arrangement guide is a decal, which can be pre-printed
with electrical components arranged for later installation.
[0038] When the component arrangement guide is used, the plurality
of electrical components are installed into the housing into a
position in the receptacle openings as indicated by the component
arrangement guide. The electrical components can be installed
before or after the power distribution module is placed into the
personal recreational vehicle. When the electrical components and
conductors are installed into the receptacle openings, each
electrical component is electrically connected to an associated
electrical conductor.
[0039] Each electrical component can be connected to its respective
electrical conductor through its respective receptacle opening by a
variety of techniques known in the art. The preferred method of
connecting is to strip any insulation off the end of the conductor
to be inserted into a receptacle opening. The stripped end is
inserted into its respective receptacle opening. Retention of the
stripped end in the receptacle opening can be enhanced by shaping
the stripped end to form fingers that will snap into one or more
recesses in a sidewall of the receptacle opening, thereby locking
the stripped end into the receptacle opening. If necessary, removal
of the stripped end from its receptacle opening is accomplished by
using an extraction tool that is inserted into the receptacle
opening opposite the electrical conductor side to push the
conductor out of the receptacle opening.
[0040] Preferably, the electrical conductors are installed before
the electrical components. After each electrical conductor is
inserted into its respective receptacle opening, each electrical
component is inserted into its appropriate location in the power
distribution module, as indicated by the component arrangement
guide. Preferably, each electrical component will have male-blade
terminals that are inserted into their respective receptacle
openings and the terminals are held into the receptacle openings
using a friction or interference fit so that the electrical
components will not fall out during operation. By using a friction
fit, an operator can remove a defective electrical component using
only fingers and no special tool is needed.
[0041] It will be clear that the present invention is well adapted
to attain the ends and advantages mentioned as well as those
inherent therein. While presently preferred embodiments have been
described for purposes of this disclosure, various changes and
modifications may be made which are well within the scope of the
present invention. For example, power distribution module can
include receptacle openings in more than one wall of the housing.
Numerous other changes may be made which will readily suggest
themselves to those skilled in the art and which are encompassed in
the spirit of the invention disclosed and as defined in the
appended claims.
* * * * *